DIY Bash Plate

[muaythaimaniac]

Hi all...

I decided that I was too tight to splash out on the ridiculous costs for a bash plate so I decided to make my own...It ended up costing less than £15

Tools required:
Jigsaw
File
Drill
rivet gun
40-50mm holesaw (optional - but makes it a lot easier!)
M5 tap (optional - dependent on fixing method)

Materials
300x400 aluminium sheet (2mm thickness) e.g. http://www.ebay.co.uk/itm/Aluminium-She ... 4ac4de4cda
Stainless steel rivets e.g. http://www.ebay.co.uk/itm/M4-8-BLIND-DO ... 35c35a5db8
Stainless steel dome head bolts and nuts e.g.http://www.ebay.co.uk/itm/M5-X-30-BUTTO ... 1c299158b1
length of aluminium strip to make brackets

How to make it:

1. Mark out sheet as shown below


2. Cut out using jigsaw and file edges


3. Mark a line half way across each of the two 'wings' and cut (this is to angle the plate back slightly)

[muaythaimaniac]

4. Offer the bash plate under the bike and bend it so that it meets the contours of the underside of the bike


5. Angle the wings back towards you to the angle you wish and mark them (make sure each side of the bike is the same)


6. Mark a line back and cut the section out


7. Once cut out, form the sheet to close the gap



8. Using off cut sheet, form a template that is the same shape and angle of the wings (Ignore the numbers on the photo - they are from the cut out parts)

[muaythaimaniac]

9. Drill and rivet this piece to the wings to give additional strength and rigidity


10. Cut 40-50mm (approx) hole so you can still access drain bolt when fitted - Ignore my uneven hole... I had a bit of an issue with my holesaw and used the jigsaw... badly!


11. Fitting the plate is down to preference. I created a bracket for the front that wrapped around the frame and drilled & tapped the frame for the rear fixing (it seemed the most logical at the time). Its up to you whether you wish to use brackets or drill & tap.

[muaythaimaniac]

And that's it... one cheapskate but strong and effective bash plate )...




The only alteration I have made since i fitted it was added a few 10mm hole to drain any collected water on the bash guard... Its up to you whether you want to do the same

[xander77]

Very nice! and a job well done, I would have done this when I was younger and didn`t have 2 kids, but I just bought a LT style one off eviBay for £35 stainless and very strong!!

Good effort from you though!!

[muaythaimaniac]

£35 and in stainless steel...bargain!

Id been watching Ebay for a while but there never seemed to be any CRM250 bash plates... They are fantastic bikes but the second hand market isnt so good

[Pie-eyedpiper]

Good job.

I got a very cheap CR one off Fleabay and had some alu checker plate welded on to double the thickness.
It stays on all the time, but have had to mod slightly to get to the water pump cover bolts.

[fallenmikethebike]

Brilliant.
Mike